CA1070229A - Method and apparatus for fabricating corrugated board from poly-coated paper - Google Patents
Method and apparatus for fabricating corrugated board from poly-coated paperInfo
- Publication number
- CA1070229A CA1070229A CA246,742A CA246742A CA1070229A CA 1070229 A CA1070229 A CA 1070229A CA 246742 A CA246742 A CA 246742A CA 1070229 A CA1070229 A CA 1070229A
- Authority
- CA
- Canada
- Prior art keywords
- web
- roll
- corrugating
- drum
- temperature
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
- B31F1/20—Corrugating; Corrugating combined with laminating to other layers
- B31F1/24—Making webs in which the channel of each corrugation is transverse to the web feed
- B31F1/26—Making webs in which the channel of each corrugation is transverse to the web feed by interengaging toothed cylinders cylinder constructions
- B31F1/28—Making webs in which the channel of each corrugation is transverse to the web feed by interengaging toothed cylinders cylinder constructions combined with uniting the corrugated webs to flat webs ; Making double-faced corrugated cardboard
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
- Y10T156/1007—Running or continuous length work
- Y10T156/1016—Transverse corrugating
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
- Y10T156/1025—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina to form undulated to corrugated sheet and securing to base with parts of shaped areas out of contact
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Machines For Manufacturing Corrugated Board In Mechanical Paper-Making Processes (AREA)
- Shaping Of Tube Ends By Bending Or Straightening (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
Corrugated board is formed by heating the plastic coated bonding surface of a liner web to a plasticizing tempera-ture against the coated surface of a rotating heating drum and, while plasticized, fusing it against the flute crests of a corru-gated medium web. The fusion bonded joints are set in the nip of a chilled pressure roll for stripping of the board unit from the corrugating roll surface. Speed of the single-face unit is primarily controlled as a function of the magnitude of angular wrap of the liner web about the heating drum. The temperature of the bonding surface of the liner web is sensed upon removal from the heating drum for the purpose of speed trim adjustment.
Corrugated board is formed by heating the plastic coated bonding surface of a liner web to a plasticizing tempera-ture against the coated surface of a rotating heating drum and, while plasticized, fusing it against the flute crests of a corru-gated medium web. The fusion bonded joints are set in the nip of a chilled pressure roll for stripping of the board unit from the corrugating roll surface. Speed of the single-face unit is primarily controlled as a function of the magnitude of angular wrap of the liner web about the heating drum. The temperature of the bonding surface of the liner web is sensed upon removal from the heating drum for the purpose of speed trim adjustment.
Description
~,~)702Z9 The present invention relates to the fabrication of ~;
corrugated board. Specifically, the present invention relates ~
to a method and apparatus for bonding a polymer plastic coated ~ -paper liner medium to a corrugated paper medium web.
Over many years of use, corrugated paper board has proven to be extremely valuable in many, various uses due to low cost and high strength to weight ratio. However, convention-al paper board has also been limited to applications where the structural product fabricated therefrom will be protected from the invasion of moisture. This is due to the dramatic loss of strength caused by moisture absorption.
Efforts in the past to protect paper-based corrugated board from moisture invasion have included both wax and plastic ~' coating of either the constituent webs prior to board fabrication or of a product assembled therefrom. Such past efforts have been less than satisfactory from several points of view.
As a water-proofing agent, wax has proven to lack the necessary strength and toughness. When applied to corrugated containers, handling abuses invariably cut or crack the wax coat-ing at some point. If moisture is present, penetration will ~
occur at the crack. -Great success has been achieved with polymer plastic as a moisture-proof cladding of a substrate paper web as des-cribed in U.S. Patent Nos. 3,849,224 to H. L. Hintz et al and 3,7~9,837 to O~ Witnes et al.
Difficulties with commercial production techniques, however, have plagued the development of poly-coated paper as a corrugated board constituent. -Simultaneous with the development of water-proofing -~
techniques for paper substrates, competitive manufacturing tech- -,' ~L~7~)~2~
niques for solid plastic web corrugated board have been developed.
Although, the s-trength of solid plastic corrugated board is generally comparable to paper base board and completely unaffect-ed by moisture, the relative cost is high and strength diminishes at higher ambient temperatures. In general, therefore, as a competitive alternative for most high moisture uses, solid plas-tic corrugated board presents a cost ceiling for plastic coated paper corrugated board.
The predominance of production problems for plastic-coated paper corrugated board center about the single facing operation where a medium web is first formed into a corrugated continuu~l between the meshing nip of two corrugating rolls Immediately thereafter while the corrugated medium is still held contiguous with the undulating surface of one of the corrugating roll pair, a liner web is bonded to the flute crests of the medium. This bonding occurs within 90 to 180 around the cor-rugating roll from the corrugating nip. Within an additional circumferential traverse of 90 to 180 about the corrugating roll, the resulting singie-~ace board is stripped from the cor-rugating roll.
At high production rates and machine speeds, the time interim between joinder and stripping may be less than one second.
This time interim is too short for the setting of most adhesives that are compatible with the plastic web coating. Accordingly, if either the liner or the medium is plastic coated, a quick setting~ hot melt adhesive ~ust be used. However~ hot melt ad-hesives are relatively very expensive for this application and, if used, the cost advantage of paper base board over solid plas-tic corrugated board is substantially lost.
As an alternative technique for bonding a liner web to ~ - 2 -. : .
~0~2~g ~:
corrugated medium web on a single facer, the adjacent plastic coat of either web may be heat plasticized to a tacky consisten-cy and then fused to the other web in the single facing nip. It - -is this technique to which the disclosure of U.S. Patent 3,811,987 to Wilkinson et al is addressed. The Wilkinson et al patent uses an open flame to heat the adjacent coat of the liner web immediately prior to the single facing nip.
Experience with the Wilkinson et al technique has been disappointing first~ from the perspective of bond uniformity due -to the non-uniform distribution of heat across the web from the burner head and~ secondly, due to consequent pin holing in over-heated areas which destroys the moisture proof objective.
Although Wilkinson et al were aware that the hond sur-face of the plastic coated liner could be sufficiently heated for plasticizing over a conventional, pre-heating drum, the technique was discounted by them because of web sticking to the drum sur~
face. However, A. L. James in his U.S. Patent Nos. 3,360,412 ;
and 3,457,139 and his Dry Lamination article published in the July, 1970 issue of Paper, Pilm and Foil Converter, pages 29-31 taught that polymer plastic film could be plasticized over heat-ed drums that were surface coated with a high temperature, non-sticking polytetrafluoroethylene resin plastic such as that available under the trade mark "Teflon".
With these tools, the problems of fusing a board liner to the corrugated medium flute crests are largely reduced to heat transfer management coordinated with speed control. ~-In the past, uncoated liner and medium webs have been preheated over heating drums to a regulated temperature by control~
ling the degree of wrap that the web is allowed to traverse over ~ ~
the drum circumference. U.S. Patent No. 3,004,880 to K. B. Lord ~ `
' ~ - 3 - ~
~07~ZZ~ :
teaches a technique whereby web temperature sensors control th~
angular position of automatically adjustable wrap control rollers.
By this technique, the machine speed is set independently by the operator and the temperature regulating mechanism adjusts the degree of web wrap about the heating drum accordingly.
Because of the relatively narrow, tolerable "dead band"
temperature for a plastic coated bonding surface, the ~ord tech-nique of temperature control tends to instability due to a con-tinuous searching or hunting of the wrap control rollers for a correct setting under only moderately variable conditions.
Additionally, if a heater drum tachnique is used for plasticizing poly-coated paper at high production speeds, a re-latively large traverse surface length is sometimes required to develop the necessary temperatures. One natural consequence of a large traverse surface length is a large diameter heater roll which is not only expensive to acquire but expensive to heat.
Some advantage may be gained, however, by using a majority of the ;
drum clrcumference as the traverse surface arc. ~owever, this expedient is encoumbered by the fact that the web supply point is fixed at a usually close proximity to the heating drum and when the heat transfer arc exceeds 180, the web course will interfere with the heater drum structure.
The present invention embodies a plurality of innova-tions which, collectively, cooperate to yield a commercially successful production of paper base, poly-coated corrugated board.
Such innovations comprise the use of compound, coordinated wrap ;~
control rollers for regulating the degree of web wrap over a large arc surface of a steam heated drum.
A polyt~trafluoroethylene coating of the pre-heating drum surface prevents sticking of the web coating to the drum `) ~ ~ 4 ~
z9 surface.
To protect the moisture barrier integrity of the poly-coated corrugating medium upon forming by the corrugating roll nip, only hot liquid water heat is transferred to the medium by the corrugating rolls.
Subsequent to the liner and medium web fusion nip, the fused, flute crest joints are chilled in the nip of a water cool-ed pressure roll to set the integxi~y of the joint for the pre-sent purpose of stripping the single-faced board from the cor-rugating roll surface. As the joint further cools, additional strength is gained.
~emperature of the liner web bonding surface is moni-tored by sensors for the purpose of machine speed control~
Accordingly, heater drum wrap magnitude is manually controlled as an independent, operator variabla and machine speed therefore be-comes a dependent variable; primarily as a function of the wrap magnitude and secondarily as a function of web temperature. Sur- ~
prisingly, little speed regulation hunting is experienced under ~;
this control scheme and the entire system quickly settles into a stable setting following a heater drum wrap adjustment. -Accordingly, the present invention provides apparatus ~
for bonding a first web to a second corrugating web, which appara- `
tus includes a pair of fluted surface corrugating cylinders ro-tatively disposed in a flute meshing nip relationship, a first , ., ~ . , .
web-heating drum mounted for rotation about a cylindrical axis thereof, and web wrap control means selectively positionable about the heating drum. The corrugating cyli~ders and the heating drum have rotational drive means and heat sources conducted there-through. A rotatable fusion roll is positioned in nip relation-ship with the heating drum and flute crests of one of the corru- ~ ~
':
- 4a ~
3~
, " ,, , ;
~)70Z;i~9 gatinq cylinders, and temperature s~nsing means is positioned ad-jacent the first web, between the nips respective to the fusion roll with the one corrugating roll and the heating drum, to detect the -temperature of the first web and generate a first electrical signal proportional to the temperature. Primary roll speed con-trol means is provided for controlling the rotational speed of the drive means as a function of the wrap control means position-ment, and secondary roll speed control means for further controls the rotational speed of the drive means as a function of the first electrical signal.
Another aspect of the present invention provides a method of fabricating corrugated board comprising a corrugating medium web and a liner web; the method including the steps of coating at least one face of the liner web with a thin laminae of polymer plastic material, heating the plastic material to a tacky consis-tency, fusing the coated surface of the liner web with the crests of corrugation flutes formed in the medium web in a nip of the fusion roll with a rotating corrugating roll, sensing the tempera-ture of the heated plastic surface immediately prior to the nip and generating a control signal as a function of temperature mea-surement, regulating the speed of board fabrication as a function of that control signal, and cooling the fused combination of the liner web and the medium web in a nip between a chilled pressure roll and the corrugating roll. ~-Reference now will be made to the accompanying drawings, wherein like reference characters designate like or similar ele-ments: -Figure 1 is a schematic illustration of the present invention ;~
showing the web flow route through the apparatus.
Figure 2 is a sectional ele~ation of the present heater drum and ;~
'' :'`'':
- 4b -~7ozzg wrap control apparatus~ ~ ?
The present invention is directed particularly to the fabrication of corrugated board from polymer plastic coated paper web. Since the coating of either or both faces of a 0.008 to 0.010 inch (.203mm to .254mm) thickness paper web with a 0~001 to 0.00075 inch (25.4~ m to 19.05,~m) surface laminae of a polymer plastic such as polyethylene, polybutylene, butyl rubber, polyisobutylene, polyvinylacetate, polyvinyl-butyral, polymethylmethacrylate, polyvinlchloride and polyamides as well known to those of ordinary skill in the art, no further attention will be paid to those processes whereby such laminated webs are formed.
However, it should be understood that the present invention also has utility in the fabrication of un~
coated paper web for otherwise conventional corru-gating processes. ~ ;;
Relative to Figure 1, there is shown a single-face corrugating station 10 comprising two, hoilow corrugating rolls 11, 12 and a hollow pressure roll 13.
: . ,.:, ~
Unconventional about the present single ~ ;
acer, is the use of hot water flow through the interior chambers of corrugating rolls 11 and 12 in lieu of steam.
Pressure roll 13 serves as a heat absorptive, chill roll and therefore, is provided with cold water .::, .
.
., ~:
: . . . . -. ~. ... . . .
, . ~: , : : : :
circulation through the interior chamber thereof in lieu of conventional steam circulation.
Fusion roll 14 is hollow for the circulation of hot water therethrough. ;
Heater roll 20 is of r latively large diameter approximately 36" diameter (385mm) and is hollow, as seen from Figure 2, for the circulation of steam therethrough. Concentric steam circulation conduits 21 and 22 are provided ~or this purpose. Conduit 22 is provided with a drop-leg 23 for condensate pickup.
The surface 30 of heater roll 20 is coated with a high temperature polymer plastic such as Teflon to prevent subsequent sticking of the polymer web coating to the heater roll surface 30.
Heater roll 20 is mounted for rotation about the axis thereof.~ Rotary power for driving it may be transmission links, not shown~ from ~he ~ corrugator roll drive motor or directly from an independent drive motor 24.
Mounted by radius arms 25 and 26, respectively, are wrap control rolls 27 and 28.
Radius arms 26 also carry a third wrap control roll ''' ~`",~''' ', '':' .
C
- 6 - , ~L070~ 9 ~ .
Outer and inner wrap control units respective to radius arms 25 and 26 are selectively posi~ionable about the heater roll axis between the maximum wrap -position illustrated in Figure I with solid lines and a minimum wrap posi~ion Ulustrated by broken lines.
Angled designates the included angle about the axis of roll 20 between the rraximum and minimum wrap positions or the outer wrap control roll 27.
n . ~ .
Angle~o designates the included angle between maximum and minimum ~ -wrap positions of the inner wrap control roll 28.
The maximum and minimum wrap positions of inner wrap control roll ;~
28 are determined by the maximum and minimum Iengths of time required by the i liner L in contact with the surface 30 of roll 20 to plasticize the polymer surface laminae of liner L contiguous with the roll surface 30. Such time periods will, of course, vary with the rotational speed of the roll 20 and the inlet steam .~ . . .
temperature.
,. ...
The maximum and minimum wrap positions of outer wrap control roll 27 a~e dependent first, on ~he maxLmum and minimum positions of inner roll 28 and second, on the approach path of web L from a supply reel not shown. In any case, it is necessary to control the routing of the web L over the entire positionment range of inner wrap control roll 28 so that no interference may occur, ZO Pursuant to these crlteria, a fixed ratio between anglesl~, and~amay be determined and the two wrap control units~ positively coordinated by ~ -suitable power transmission links such as sprockets 41 and 42. ~
Sprocket 41 ls non-rotatively secured to radius arm 25 and sprocket 42 is secured to radius arm 26, Roller chains 43 and 44 transmit control movement : . :
from respectlve driver sprockets 45 and 46. Both driver sprockets are , , non-rotati~ely secured to the output shaft 48 of wrap control motor 47.
The ratios be~ween sprockets 41-45 and 42-46 are selected to yield .
.~. ' , ~
1~7~Z~9 the desired ratio between angles ~L and ~ relative to rotation of the common power shaft from motor 47.
In operation, the degree of wrap contact between the liner web L and heater roll surface 30 is manually determined and set pursuant to a multiplicity of Lmmediately relevant criteria. Accordingly, the wrap control motor is manually regulated by a polarity reversing switch 50, the closure of which determines the direction motor 47 rotation. Switch 50 is held closed by the operator until the inner wrap control roll 28 is driven to the deslred location about the heater roll circumference.
I0 Simultaneous with the setting of the wrap control rolls, driver sprocket 51, non-rotatively secured to motor shaft 45, drives a speed control follower sprocket 53 via transmission chain 52. The follower sprocket 53 and conductive stylus 55 are non-rotatively secured to follower shaft 54. The distal end of stylus 55 contacts Witll the resistance winding 56 of a primary speed control rheostat 57. In circuit with the primary speed control winding 56 across a reference power source R
are two temperature trimming rheostats 61a and 61b. Both trimming rheostats 61 have matched resistance windings 62a and 62b. Each trim resistance 62 provides a . ~ .
magnitùde of resistance in the speed control circuit which is selected as a percentage of primary control reslstance 56, 20% for example. Since the trim - 20 rheostats 61 are connected for opposite-hand operatlon on respectL~e sLdes of the prlmary rheostat 57, the total resisthe load across the reference power source R
remains constant. Any r~agnitude of resistance added to the total circuit by trim :. , .. ~:
rheostat 61b, resistance of the same magnitude is reduced by rheostat 61a. -The contact styli of trim xheostats 61 are simultaneously driven by actuator 63 which responds, proportionally, to slgnals from a temperature sensor 64.
The rotational speed of the main drive motor 24 is controlled , conventionally by a relatlve voItage motor control device 70 which regulates . -107~ZZ~
the supply of power from a convenient generation source G. Basically, power supply and hence, responsive speed, is regulated as a percentage of a maximuum.
Accordingly, motor controller 70 is provided by conduits with a constant reference voltage acxoss source R. For speed regulation comparison, stylus conduit 58 provides a variable voItage derived across the resistances 62b and 56. The speed of motor 24, therefore, becomes a percentage of conduit 58 voltage as compared to the maximuum available voltage across conduits 65 and 66.
From the foregoing description, it may now be understood that as the i; ;~
,, ~ - operator sets the position of the wrap control roll 27 and 28 by a functioning of the -polari~ reversing switch 50, resistance in the primary speed control rheostat 57 between the reference power source R and the stylus 55 is determined accordingly.
Subject to the trim resistance of rheostat 6 lb)the resulting voltage in stylus conduit ' 5~ determines the running speed of motor 24. `
! ` Temperature sensor 64 is manually set to sensitivity of the desired .: ~
f~ web L temperature. Should the actual temperature of the web rise above the desired temperature the actuator 63 will be driven in one direction by a displacement magnitude proportional to the difference between the desired and actual ~emperatures.
, ~ ~ The actuator 63 displacement will consequently increase the voltage drop across resistance 62b but reduce the drop across resistance 62a. Consequently, tlle voltage at stylus conduit 58 is 1ncreased but the total drop across reference source R i9 unchanged. Because of the increased voltage in conduit 58, the proportion thereof `~
to the total across reference conduits 65 and 66 is increased to increase the speed ;, of motor 24 proportionately. Such increased speed reduces the residence time o~
' web L against ~he heater roll surface 30 thereby reducing the web temperature at the point of temperature sensor 64, Collectively, the present Invention operates as follows, A web of ; ~ ~ -corrugating medium M ls received from a supply reel, not shown, and routed into .
.
~702Z9 the meshing nip between corrugating rolls 11 and 12. Simultalleously, lleat is , ~ conductively transferred to the medium M from the hot water source f~owing within rolls 11 and 12.
., .
.' ~ Subsequent to forming, the corrugated continuum of medium M is :
maintained in contiguous contact with the heater roll 11 into the nip with fusion roll 14 where the plasticizecl surface of liner web L is pressed into bonding contact ~j with the corrugated flute crests of medium M.
Intimate surface contact between the medium M and the roll 11 is ',~ : :'.
continued into the nip with the pressure roll 13 where, under the nip pressure, $~ .: 10 sufficient heat ls withdrawn from the bonded joint between the flute crests of medium M and the liner L ~o set the joint, Thereafter, the integrated unit of webs :~
~ M and L constituting single-face board B is withdrawn from the single-facing unit :,~ 10 for further processing.
Prior to entry into the fusion nip, liner web L is drawn from a supply ~; reel, not shown, and routed over the outer wrap control roller 27 and around the ,~,, ;.. . :`
~i inner wrap control roller 28. Regardless of the degree of wrap contac~ with heater roll surface 30 desired, liner web L wili always approach the surface 30 at the ~;~
.;~ . same angle of tangency, relatiYe to the inner wrap control roll 28. .
~: . Depending on the plasticizing temperature of the p~rticular surface laminae on the web L, 210F (98C) for a one mil (25,4~ M) thickness of ¦ . corona treated polyethylene, for example, and the present steam temperature t~ ', circulated within heater roll 20, .inn~r wrap control roll 28 is manually set at a desired pos,tlon around the heater roll 20 circumference.
If corona treatment, as described in the July, 1970 Paper, Film and . Foil Converter article by A. L. James, is not used, the plasticlzLng temperature ~.
.,, ~ , .
. ~ . . of the laminae will be signlficantly increased. In the present example, a non-oorona treated lamina plasticizing tempera~ure wLll be in the order of 23ûF ~110C).
' ~, -10- ' ,~ -, , ~ : :,.
~ ~0229 ~1 i, -Known properties of the plastic laminae and running experience will " ~.
determine the exact temperature range that is to be monitored by the ~hermocouple ;
50 control which, in the given example, will be 208 to 212F (97. 8 to 100 C).
s The desired condition of the plastic is the lowest temperature to yield a tacky, soft ~ result. Higher temperatures induce an out-gassing of the substrate paper contained ~
,, , :
f ` moisture in the form of steam so as to leave what is known as pin holes in the plastic coatlng continuity. Such pin holing permits subsequent absorption of moisture by the paper substrate which dramatically reduces wet-strength of the corrugated board product.
. . . .
, ; 10 Having selected a set position for the inner wrap control roller 28, speed control follower rheostat 57 sets a corresponding, previously calibrated, .f~ speed for both, the corrugating rolls 11, 12 and the heater roll 20. Should the re-~j' .'1 ' ~, sulting speed fail to yield the desired temperature to the bonding face of liner web L, trim rheostats 61a, 61b, responsive to the temperature sensor 64, will further adjust and continuously maintain the speed to the desired end.
,, " ~ . . .
,, :-.
' ~
~, 20 . . ' ~
.
~ !
:, ~ ' :, ,. :, :
~,: ' ' '~.;
,s``,'' '; :: - :~
,,: , ,. . .
corrugated board. Specifically, the present invention relates ~
to a method and apparatus for bonding a polymer plastic coated ~ -paper liner medium to a corrugated paper medium web.
Over many years of use, corrugated paper board has proven to be extremely valuable in many, various uses due to low cost and high strength to weight ratio. However, convention-al paper board has also been limited to applications where the structural product fabricated therefrom will be protected from the invasion of moisture. This is due to the dramatic loss of strength caused by moisture absorption.
Efforts in the past to protect paper-based corrugated board from moisture invasion have included both wax and plastic ~' coating of either the constituent webs prior to board fabrication or of a product assembled therefrom. Such past efforts have been less than satisfactory from several points of view.
As a water-proofing agent, wax has proven to lack the necessary strength and toughness. When applied to corrugated containers, handling abuses invariably cut or crack the wax coat-ing at some point. If moisture is present, penetration will ~
occur at the crack. -Great success has been achieved with polymer plastic as a moisture-proof cladding of a substrate paper web as des-cribed in U.S. Patent Nos. 3,849,224 to H. L. Hintz et al and 3,7~9,837 to O~ Witnes et al.
Difficulties with commercial production techniques, however, have plagued the development of poly-coated paper as a corrugated board constituent. -Simultaneous with the development of water-proofing -~
techniques for paper substrates, competitive manufacturing tech- -,' ~L~7~)~2~
niques for solid plastic web corrugated board have been developed.
Although, the s-trength of solid plastic corrugated board is generally comparable to paper base board and completely unaffect-ed by moisture, the relative cost is high and strength diminishes at higher ambient temperatures. In general, therefore, as a competitive alternative for most high moisture uses, solid plas-tic corrugated board presents a cost ceiling for plastic coated paper corrugated board.
The predominance of production problems for plastic-coated paper corrugated board center about the single facing operation where a medium web is first formed into a corrugated continuu~l between the meshing nip of two corrugating rolls Immediately thereafter while the corrugated medium is still held contiguous with the undulating surface of one of the corrugating roll pair, a liner web is bonded to the flute crests of the medium. This bonding occurs within 90 to 180 around the cor-rugating roll from the corrugating nip. Within an additional circumferential traverse of 90 to 180 about the corrugating roll, the resulting singie-~ace board is stripped from the cor-rugating roll.
At high production rates and machine speeds, the time interim between joinder and stripping may be less than one second.
This time interim is too short for the setting of most adhesives that are compatible with the plastic web coating. Accordingly, if either the liner or the medium is plastic coated, a quick setting~ hot melt adhesive ~ust be used. However~ hot melt ad-hesives are relatively very expensive for this application and, if used, the cost advantage of paper base board over solid plas-tic corrugated board is substantially lost.
As an alternative technique for bonding a liner web to ~ - 2 -. : .
~0~2~g ~:
corrugated medium web on a single facer, the adjacent plastic coat of either web may be heat plasticized to a tacky consisten-cy and then fused to the other web in the single facing nip. It - -is this technique to which the disclosure of U.S. Patent 3,811,987 to Wilkinson et al is addressed. The Wilkinson et al patent uses an open flame to heat the adjacent coat of the liner web immediately prior to the single facing nip.
Experience with the Wilkinson et al technique has been disappointing first~ from the perspective of bond uniformity due -to the non-uniform distribution of heat across the web from the burner head and~ secondly, due to consequent pin holing in over-heated areas which destroys the moisture proof objective.
Although Wilkinson et al were aware that the hond sur-face of the plastic coated liner could be sufficiently heated for plasticizing over a conventional, pre-heating drum, the technique was discounted by them because of web sticking to the drum sur~
face. However, A. L. James in his U.S. Patent Nos. 3,360,412 ;
and 3,457,139 and his Dry Lamination article published in the July, 1970 issue of Paper, Pilm and Foil Converter, pages 29-31 taught that polymer plastic film could be plasticized over heat-ed drums that were surface coated with a high temperature, non-sticking polytetrafluoroethylene resin plastic such as that available under the trade mark "Teflon".
With these tools, the problems of fusing a board liner to the corrugated medium flute crests are largely reduced to heat transfer management coordinated with speed control. ~-In the past, uncoated liner and medium webs have been preheated over heating drums to a regulated temperature by control~
ling the degree of wrap that the web is allowed to traverse over ~ ~
the drum circumference. U.S. Patent No. 3,004,880 to K. B. Lord ~ `
' ~ - 3 - ~
~07~ZZ~ :
teaches a technique whereby web temperature sensors control th~
angular position of automatically adjustable wrap control rollers.
By this technique, the machine speed is set independently by the operator and the temperature regulating mechanism adjusts the degree of web wrap about the heating drum accordingly.
Because of the relatively narrow, tolerable "dead band"
temperature for a plastic coated bonding surface, the ~ord tech-nique of temperature control tends to instability due to a con-tinuous searching or hunting of the wrap control rollers for a correct setting under only moderately variable conditions.
Additionally, if a heater drum tachnique is used for plasticizing poly-coated paper at high production speeds, a re-latively large traverse surface length is sometimes required to develop the necessary temperatures. One natural consequence of a large traverse surface length is a large diameter heater roll which is not only expensive to acquire but expensive to heat.
Some advantage may be gained, however, by using a majority of the ;
drum clrcumference as the traverse surface arc. ~owever, this expedient is encoumbered by the fact that the web supply point is fixed at a usually close proximity to the heating drum and when the heat transfer arc exceeds 180, the web course will interfere with the heater drum structure.
The present invention embodies a plurality of innova-tions which, collectively, cooperate to yield a commercially successful production of paper base, poly-coated corrugated board.
Such innovations comprise the use of compound, coordinated wrap ;~
control rollers for regulating the degree of web wrap over a large arc surface of a steam heated drum.
A polyt~trafluoroethylene coating of the pre-heating drum surface prevents sticking of the web coating to the drum `) ~ ~ 4 ~
z9 surface.
To protect the moisture barrier integrity of the poly-coated corrugating medium upon forming by the corrugating roll nip, only hot liquid water heat is transferred to the medium by the corrugating rolls.
Subsequent to the liner and medium web fusion nip, the fused, flute crest joints are chilled in the nip of a water cool-ed pressure roll to set the integxi~y of the joint for the pre-sent purpose of stripping the single-faced board from the cor-rugating roll surface. As the joint further cools, additional strength is gained.
~emperature of the liner web bonding surface is moni-tored by sensors for the purpose of machine speed control~
Accordingly, heater drum wrap magnitude is manually controlled as an independent, operator variabla and machine speed therefore be-comes a dependent variable; primarily as a function of the wrap magnitude and secondarily as a function of web temperature. Sur- ~
prisingly, little speed regulation hunting is experienced under ~;
this control scheme and the entire system quickly settles into a stable setting following a heater drum wrap adjustment. -Accordingly, the present invention provides apparatus ~
for bonding a first web to a second corrugating web, which appara- `
tus includes a pair of fluted surface corrugating cylinders ro-tatively disposed in a flute meshing nip relationship, a first , ., ~ . , .
web-heating drum mounted for rotation about a cylindrical axis thereof, and web wrap control means selectively positionable about the heating drum. The corrugating cyli~ders and the heating drum have rotational drive means and heat sources conducted there-through. A rotatable fusion roll is positioned in nip relation-ship with the heating drum and flute crests of one of the corru- ~ ~
':
- 4a ~
3~
, " ,, , ;
~)70Z;i~9 gatinq cylinders, and temperature s~nsing means is positioned ad-jacent the first web, between the nips respective to the fusion roll with the one corrugating roll and the heating drum, to detect the -temperature of the first web and generate a first electrical signal proportional to the temperature. Primary roll speed con-trol means is provided for controlling the rotational speed of the drive means as a function of the wrap control means position-ment, and secondary roll speed control means for further controls the rotational speed of the drive means as a function of the first electrical signal.
Another aspect of the present invention provides a method of fabricating corrugated board comprising a corrugating medium web and a liner web; the method including the steps of coating at least one face of the liner web with a thin laminae of polymer plastic material, heating the plastic material to a tacky consis-tency, fusing the coated surface of the liner web with the crests of corrugation flutes formed in the medium web in a nip of the fusion roll with a rotating corrugating roll, sensing the tempera-ture of the heated plastic surface immediately prior to the nip and generating a control signal as a function of temperature mea-surement, regulating the speed of board fabrication as a function of that control signal, and cooling the fused combination of the liner web and the medium web in a nip between a chilled pressure roll and the corrugating roll. ~-Reference now will be made to the accompanying drawings, wherein like reference characters designate like or similar ele-ments: -Figure 1 is a schematic illustration of the present invention ;~
showing the web flow route through the apparatus.
Figure 2 is a sectional ele~ation of the present heater drum and ;~
'' :'`'':
- 4b -~7ozzg wrap control apparatus~ ~ ?
The present invention is directed particularly to the fabrication of corrugated board from polymer plastic coated paper web. Since the coating of either or both faces of a 0.008 to 0.010 inch (.203mm to .254mm) thickness paper web with a 0~001 to 0.00075 inch (25.4~ m to 19.05,~m) surface laminae of a polymer plastic such as polyethylene, polybutylene, butyl rubber, polyisobutylene, polyvinylacetate, polyvinyl-butyral, polymethylmethacrylate, polyvinlchloride and polyamides as well known to those of ordinary skill in the art, no further attention will be paid to those processes whereby such laminated webs are formed.
However, it should be understood that the present invention also has utility in the fabrication of un~
coated paper web for otherwise conventional corru-gating processes. ~ ;;
Relative to Figure 1, there is shown a single-face corrugating station 10 comprising two, hoilow corrugating rolls 11, 12 and a hollow pressure roll 13.
: . ,.:, ~
Unconventional about the present single ~ ;
acer, is the use of hot water flow through the interior chambers of corrugating rolls 11 and 12 in lieu of steam.
Pressure roll 13 serves as a heat absorptive, chill roll and therefore, is provided with cold water .::, .
.
., ~:
: . . . . -. ~. ... . . .
, . ~: , : : : :
circulation through the interior chamber thereof in lieu of conventional steam circulation.
Fusion roll 14 is hollow for the circulation of hot water therethrough. ;
Heater roll 20 is of r latively large diameter approximately 36" diameter (385mm) and is hollow, as seen from Figure 2, for the circulation of steam therethrough. Concentric steam circulation conduits 21 and 22 are provided ~or this purpose. Conduit 22 is provided with a drop-leg 23 for condensate pickup.
The surface 30 of heater roll 20 is coated with a high temperature polymer plastic such as Teflon to prevent subsequent sticking of the polymer web coating to the heater roll surface 30.
Heater roll 20 is mounted for rotation about the axis thereof.~ Rotary power for driving it may be transmission links, not shown~ from ~he ~ corrugator roll drive motor or directly from an independent drive motor 24.
Mounted by radius arms 25 and 26, respectively, are wrap control rolls 27 and 28.
Radius arms 26 also carry a third wrap control roll ''' ~`",~''' ', '':' .
C
- 6 - , ~L070~ 9 ~ .
Outer and inner wrap control units respective to radius arms 25 and 26 are selectively posi~ionable about the heater roll axis between the maximum wrap -position illustrated in Figure I with solid lines and a minimum wrap posi~ion Ulustrated by broken lines.
Angled designates the included angle about the axis of roll 20 between the rraximum and minimum wrap positions or the outer wrap control roll 27.
n . ~ .
Angle~o designates the included angle between maximum and minimum ~ -wrap positions of the inner wrap control roll 28.
The maximum and minimum wrap positions of inner wrap control roll ;~
28 are determined by the maximum and minimum Iengths of time required by the i liner L in contact with the surface 30 of roll 20 to plasticize the polymer surface laminae of liner L contiguous with the roll surface 30. Such time periods will, of course, vary with the rotational speed of the roll 20 and the inlet steam .~ . . .
temperature.
,. ...
The maximum and minimum wrap positions of outer wrap control roll 27 a~e dependent first, on ~he maxLmum and minimum positions of inner roll 28 and second, on the approach path of web L from a supply reel not shown. In any case, it is necessary to control the routing of the web L over the entire positionment range of inner wrap control roll 28 so that no interference may occur, ZO Pursuant to these crlteria, a fixed ratio between anglesl~, and~amay be determined and the two wrap control units~ positively coordinated by ~ -suitable power transmission links such as sprockets 41 and 42. ~
Sprocket 41 ls non-rotatively secured to radius arm 25 and sprocket 42 is secured to radius arm 26, Roller chains 43 and 44 transmit control movement : . :
from respectlve driver sprockets 45 and 46. Both driver sprockets are , , non-rotati~ely secured to the output shaft 48 of wrap control motor 47.
The ratios be~ween sprockets 41-45 and 42-46 are selected to yield .
.~. ' , ~
1~7~Z~9 the desired ratio between angles ~L and ~ relative to rotation of the common power shaft from motor 47.
In operation, the degree of wrap contact between the liner web L and heater roll surface 30 is manually determined and set pursuant to a multiplicity of Lmmediately relevant criteria. Accordingly, the wrap control motor is manually regulated by a polarity reversing switch 50, the closure of which determines the direction motor 47 rotation. Switch 50 is held closed by the operator until the inner wrap control roll 28 is driven to the deslred location about the heater roll circumference.
I0 Simultaneous with the setting of the wrap control rolls, driver sprocket 51, non-rotatively secured to motor shaft 45, drives a speed control follower sprocket 53 via transmission chain 52. The follower sprocket 53 and conductive stylus 55 are non-rotatively secured to follower shaft 54. The distal end of stylus 55 contacts Witll the resistance winding 56 of a primary speed control rheostat 57. In circuit with the primary speed control winding 56 across a reference power source R
are two temperature trimming rheostats 61a and 61b. Both trimming rheostats 61 have matched resistance windings 62a and 62b. Each trim resistance 62 provides a . ~ .
magnitùde of resistance in the speed control circuit which is selected as a percentage of primary control reslstance 56, 20% for example. Since the trim - 20 rheostats 61 are connected for opposite-hand operatlon on respectL~e sLdes of the prlmary rheostat 57, the total resisthe load across the reference power source R
remains constant. Any r~agnitude of resistance added to the total circuit by trim :. , .. ~:
rheostat 61b, resistance of the same magnitude is reduced by rheostat 61a. -The contact styli of trim xheostats 61 are simultaneously driven by actuator 63 which responds, proportionally, to slgnals from a temperature sensor 64.
The rotational speed of the main drive motor 24 is controlled , conventionally by a relatlve voItage motor control device 70 which regulates . -107~ZZ~
the supply of power from a convenient generation source G. Basically, power supply and hence, responsive speed, is regulated as a percentage of a maximuum.
Accordingly, motor controller 70 is provided by conduits with a constant reference voltage acxoss source R. For speed regulation comparison, stylus conduit 58 provides a variable voItage derived across the resistances 62b and 56. The speed of motor 24, therefore, becomes a percentage of conduit 58 voltage as compared to the maximuum available voltage across conduits 65 and 66.
From the foregoing description, it may now be understood that as the i; ;~
,, ~ - operator sets the position of the wrap control roll 27 and 28 by a functioning of the -polari~ reversing switch 50, resistance in the primary speed control rheostat 57 between the reference power source R and the stylus 55 is determined accordingly.
Subject to the trim resistance of rheostat 6 lb)the resulting voltage in stylus conduit ' 5~ determines the running speed of motor 24. `
! ` Temperature sensor 64 is manually set to sensitivity of the desired .: ~
f~ web L temperature. Should the actual temperature of the web rise above the desired temperature the actuator 63 will be driven in one direction by a displacement magnitude proportional to the difference between the desired and actual ~emperatures.
, ~ ~ The actuator 63 displacement will consequently increase the voltage drop across resistance 62b but reduce the drop across resistance 62a. Consequently, tlle voltage at stylus conduit 58 is 1ncreased but the total drop across reference source R i9 unchanged. Because of the increased voltage in conduit 58, the proportion thereof `~
to the total across reference conduits 65 and 66 is increased to increase the speed ;, of motor 24 proportionately. Such increased speed reduces the residence time o~
' web L against ~he heater roll surface 30 thereby reducing the web temperature at the point of temperature sensor 64, Collectively, the present Invention operates as follows, A web of ; ~ ~ -corrugating medium M ls received from a supply reel, not shown, and routed into .
.
~702Z9 the meshing nip between corrugating rolls 11 and 12. Simultalleously, lleat is , ~ conductively transferred to the medium M from the hot water source f~owing within rolls 11 and 12.
., .
.' ~ Subsequent to forming, the corrugated continuum of medium M is :
maintained in contiguous contact with the heater roll 11 into the nip with fusion roll 14 where the plasticizecl surface of liner web L is pressed into bonding contact ~j with the corrugated flute crests of medium M.
Intimate surface contact between the medium M and the roll 11 is ',~ : :'.
continued into the nip with the pressure roll 13 where, under the nip pressure, $~ .: 10 sufficient heat ls withdrawn from the bonded joint between the flute crests of medium M and the liner L ~o set the joint, Thereafter, the integrated unit of webs :~
~ M and L constituting single-face board B is withdrawn from the single-facing unit :,~ 10 for further processing.
Prior to entry into the fusion nip, liner web L is drawn from a supply ~; reel, not shown, and routed over the outer wrap control roller 27 and around the ,~,, ;.. . :`
~i inner wrap control roller 28. Regardless of the degree of wrap contac~ with heater roll surface 30 desired, liner web L wili always approach the surface 30 at the ~;~
.;~ . same angle of tangency, relatiYe to the inner wrap control roll 28. .
~: . Depending on the plasticizing temperature of the p~rticular surface laminae on the web L, 210F (98C) for a one mil (25,4~ M) thickness of ¦ . corona treated polyethylene, for example, and the present steam temperature t~ ', circulated within heater roll 20, .inn~r wrap control roll 28 is manually set at a desired pos,tlon around the heater roll 20 circumference.
If corona treatment, as described in the July, 1970 Paper, Film and . Foil Converter article by A. L. James, is not used, the plasticlzLng temperature ~.
.,, ~ , .
. ~ . . of the laminae will be signlficantly increased. In the present example, a non-oorona treated lamina plasticizing tempera~ure wLll be in the order of 23ûF ~110C).
' ~, -10- ' ,~ -, , ~ : :,.
~ ~0229 ~1 i, -Known properties of the plastic laminae and running experience will " ~.
determine the exact temperature range that is to be monitored by the ~hermocouple ;
50 control which, in the given example, will be 208 to 212F (97. 8 to 100 C).
s The desired condition of the plastic is the lowest temperature to yield a tacky, soft ~ result. Higher temperatures induce an out-gassing of the substrate paper contained ~
,, , :
f ` moisture in the form of steam so as to leave what is known as pin holes in the plastic coatlng continuity. Such pin holing permits subsequent absorption of moisture by the paper substrate which dramatically reduces wet-strength of the corrugated board product.
. . . .
, ; 10 Having selected a set position for the inner wrap control roller 28, speed control follower rheostat 57 sets a corresponding, previously calibrated, .f~ speed for both, the corrugating rolls 11, 12 and the heater roll 20. Should the re-~j' .'1 ' ~, sulting speed fail to yield the desired temperature to the bonding face of liner web L, trim rheostats 61a, 61b, responsive to the temperature sensor 64, will further adjust and continuously maintain the speed to the desired end.
,, " ~ . . .
,, :-.
' ~
~, 20 . . ' ~
.
~ !
:, ~ ' :, ,. :, :
~,: ' ' '~.;
,s``,'' '; :: - :~
,,: , ,. . .
Claims (13)
1. Apparatus for bonding a first web to a second cor-rugated web, said apparatus comprising:
a pair of fluted-surface corrugating cylinders rotatively dis-posed in a flute-meshing nip relationship;
a first web-heating drum mounted for rotation about a cylindrical axis thereof, said corrugating cylinders and said heating drum having rotational drive means and heat sources conducted there-through;
web wrap control means selectively positionable about said heat-ing drum;
a rotatable fusion roll positioned in nip relationship with said heating drum and flute crests of one of said corrugating cylin-ders;
temperature sensing means positioned adjacent said first web, between said nips respective to said fusion roll with said one corrugating roll and said heating drum, to detect the temperature of said first web and generate a first electrical signal propor-tional to said temperature;
primary roll speed control means for controlling the rotational speed of said drive means as a function of said wrap control means positionment; and, secondary roll speed control means for further controlling the rotational speed of said drive means as a function of said first signal.
a pair of fluted-surface corrugating cylinders rotatively dis-posed in a flute-meshing nip relationship;
a first web-heating drum mounted for rotation about a cylindrical axis thereof, said corrugating cylinders and said heating drum having rotational drive means and heat sources conducted there-through;
web wrap control means selectively positionable about said heat-ing drum;
a rotatable fusion roll positioned in nip relationship with said heating drum and flute crests of one of said corrugating cylin-ders;
temperature sensing means positioned adjacent said first web, between said nips respective to said fusion roll with said one corrugating roll and said heating drum, to detect the temperature of said first web and generate a first electrical signal propor-tional to said temperature;
primary roll speed control means for controlling the rotational speed of said drive means as a function of said wrap control means positionment; and, secondary roll speed control means for further controlling the rotational speed of said drive means as a function of said first signal.
2. Apparatus as defined in claim 1, wherein said heat-ing drum heat source comprises steam flow conducted through a chamber within said heating drum, and said corrugating cylinder heat source comprises heated water conducted through flow cham-bers therewithin.
3. Apparatus as defined in claim 2, wherein a pressure roll is positioned in nip relationship with said flute crests of said one corrugating roll, said pressure roll having a fluid heat sink medium conducted therethrough.
4. Apparatus as defined in claim 1, 2, or 3, wherein said wrap control means comprise first and second wrap control rolls disposed axially parallel with said heating drum between respective pairs of radius arms, said first wrap control roll being positioned more proximate of the surface of said heating drum than said second wrap control roll, and rotational power and transmission means coupled to said radius arms to coordinate the arcuate positionment of said wrap control rolls about the cylin-drical axis of said heating drum.
5. Apparatus for bonding a first web to a second cor-rugated web, said apparatus comprising:
a pair of fluted-surface corrugating cylinders rotatively dis-posed in a flute-meshing nip relationship;
a first web-heating drum mounted for rotation about a cylindrical axis thereof, said corrugating cylinders and said web-heating drum having rotational drive means and heat sources conducted therethrough;
web wrap control means selectively positionable about said heat-ing drum and including inner and outer wrap control rolls, each being selectively positionable about respective arcs relative to said cylindrical axis;
a rotatable fusion roll positioned in nip relationship with said heating drum and flute crests of one of said corrugating cylin-ders;
temperature sensing means positioned adjacent said first web, between said nips respective to said fusion roll with said one corrugating roll and said heater drum, to detect the temperature of said first web and generate a first electrical signal propor-tional to said temperature;
primary speed regulation means adjusted as a function of the arcu-ate positionment of said wrap control means for controlling the rotational speed of said heating drum and corrugating roll rota-tional drive means;
speed trim adjusting means responsive to said first signal to further control the rotational speed of said drive means; and rotational power transmission means coupled to said wrap control rolls with a rotational ratio proportional to a ratio between said respecting arcs whereby the arcuate positionment of said outer wrap control roll is coordinated with the arcuate place-ment of said inner wrap control roll.
a pair of fluted-surface corrugating cylinders rotatively dis-posed in a flute-meshing nip relationship;
a first web-heating drum mounted for rotation about a cylindrical axis thereof, said corrugating cylinders and said web-heating drum having rotational drive means and heat sources conducted therethrough;
web wrap control means selectively positionable about said heat-ing drum and including inner and outer wrap control rolls, each being selectively positionable about respective arcs relative to said cylindrical axis;
a rotatable fusion roll positioned in nip relationship with said heating drum and flute crests of one of said corrugating cylin-ders;
temperature sensing means positioned adjacent said first web, between said nips respective to said fusion roll with said one corrugating roll and said heater drum, to detect the temperature of said first web and generate a first electrical signal propor-tional to said temperature;
primary speed regulation means adjusted as a function of the arcu-ate positionment of said wrap control means for controlling the rotational speed of said heating drum and corrugating roll rota-tional drive means;
speed trim adjusting means responsive to said first signal to further control the rotational speed of said drive means; and rotational power transmission means coupled to said wrap control rolls with a rotational ratio proportional to a ratio between said respecting arcs whereby the arcuate positionment of said outer wrap control roll is coordinated with the arcuate place-ment of said inner wrap control roll.
6. Apparatus as defined in claim 5, wherein said pri-mary speed regulation means comprises first variable resistance means in a motor speed control circuit for said drive means, said variable resistance being adjusted by said power transmission means.
7. Apparatus as defined in claim 6, wherein said speed trim adjusting means comprises second variable resistance means in said motor speed control circuit and actuator means responsive to said first signal to adjust said second variable resistance means.
8. Apparatus as defined in claim 5 wherein the heat sources respective to said corrugating cylinders are liquid flow streams of heated water.
9. Apparatus as defined in claim 8, wherein the heat source respective to said heating drum is a vapor flow stream of steam.
10. Apparatus as defined in claim 9, wherein said fusion roll is provided with a heat source flow conduit therein.
11. Apparatus as defined in claim 9, wherein a pressure roll is positioned in nip relationship with said flute crests of said one corrugating roll, said pressure roll having a fluid heat sink medium conducted therethrough.
12. A method for fabricating corrugated board compris-ing a corrugated medium web and a liner web, said method including the steps of:
coating at least one surface of said liner web with a thin laminae of polymer plastic material;
heating said polymer plastic laminate to a tacky consistency;
fusing the heated plastic surface of said liner web to the crests of corrugation flutes in said medium web at a nip between a heat-ed fusion roll and a medium web corrugating roll;
sensing the temperature of said heated plastic surface immediate-ly prior to said nip;
comparing the temperature of said heated plastic surface to a desired temperature range; and regulating the speed of said corrugating roll in response to said temperature comparison.
coating at least one surface of said liner web with a thin laminae of polymer plastic material;
heating said polymer plastic laminate to a tacky consistency;
fusing the heated plastic surface of said liner web to the crests of corrugation flutes in said medium web at a nip between a heat-ed fusion roll and a medium web corrugating roll;
sensing the temperature of said heated plastic surface immediate-ly prior to said nip;
comparing the temperature of said heated plastic surface to a desired temperature range; and regulating the speed of said corrugating roll in response to said temperature comparison.
13. A method of fabricating corrugated board compris-ing a corrugated medium web and a liner web, said method includ-ing the steps of:
coating at least one face of said liner web with a thin laminae of polymer plastic material;
contacting said coated face of said liner web against the sur-face of a rotating heater drum for a time period sufficient to soften said plastic material to a tacky consistency;
peeling said liner web from the surface of said heater drum at a first nip of a heated fusion roll with said heater drum;
fusing the coated surface of said liner web with the crests of corrugation flutes formed in said medium web in a second nip of said fusion roll with a rotating corrugating roll;
measuring the temperature of said coated surface between said heater drum and said corrugating roll;
generating a control signal as a function of said temperature measurement;
regulating the speed of said board fabrication as a function of said control signal; and cooling the fused combination of said liner web and said medium web in a nip between a chilled pressure roll and said corrugating roll.
coating at least one face of said liner web with a thin laminae of polymer plastic material;
contacting said coated face of said liner web against the sur-face of a rotating heater drum for a time period sufficient to soften said plastic material to a tacky consistency;
peeling said liner web from the surface of said heater drum at a first nip of a heated fusion roll with said heater drum;
fusing the coated surface of said liner web with the crests of corrugation flutes formed in said medium web in a second nip of said fusion roll with a rotating corrugating roll;
measuring the temperature of said coated surface between said heater drum and said corrugating roll;
generating a control signal as a function of said temperature measurement;
regulating the speed of said board fabrication as a function of said control signal; and cooling the fused combination of said liner web and said medium web in a nip between a chilled pressure roll and said corrugating roll.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US05/593,833 US4038122A (en) | 1975-07-07 | 1975-07-07 | Method and apparatus for fabricating corrugated board from poly-coated paper |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1070229A true CA1070229A (en) | 1980-01-22 |
Family
ID=24376382
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA246,742A Expired CA1070229A (en) | 1975-07-07 | 1976-02-27 | Method and apparatus for fabricating corrugated board from poly-coated paper |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US4038122A (en) |
| JP (1) | JPS5224797A (en) |
| CA (1) | CA1070229A (en) |
Families Citing this family (14)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4202723A (en) * | 1977-01-10 | 1980-05-13 | Westvaco Corporation | Automatically controlled machine for making double-face, polymer plastic coated, corrugated paperboard |
| US4250797A (en) * | 1978-12-28 | 1981-02-17 | Consolidated Foods Corp. | Apparatus for making corrugated packages |
| US4333786A (en) * | 1980-02-27 | 1982-06-08 | Inmont Corporation | Laminating |
| JPS6228006Y2 (en) * | 1981-04-20 | 1987-07-18 | ||
| US4871406A (en) * | 1988-03-16 | 1989-10-03 | Nekoosa Packaging Corporation | Process for on-line lamination of plastic |
| AU609267B2 (en) * | 1988-03-16 | 1991-04-26 | Nekoosa Packaging Corporation | Method of making a plastic film laminated corrugated paperboard |
| JPH0617536Y2 (en) * | 1989-03-06 | 1994-05-11 | 株式会社磯輪鉄工所 | Preheater heating amount adjustment device for corrugated board manufacturing machine |
| JPH07308981A (en) * | 1994-05-16 | 1995-11-28 | Isowa Corp | Belt speed controller for manufacture of one side corrugated fiberboard manufacture |
| EP0739711B1 (en) * | 1995-04-24 | 1998-12-23 | PETERS MASCHINENFABRIK GmbH | Smooth press for a machine for producing cardboard |
| US5894681A (en) * | 1995-05-01 | 1999-04-20 | Inland Container Corporation | Automated fabrication of corrugated paper products |
| US5527408A (en) * | 1995-06-16 | 1996-06-18 | Allen; George H. | Method and apparatus for automatically controlling the moisture content of corrugated board |
| US5865953A (en) * | 1996-08-30 | 1999-02-02 | Merrimac Paper Company, Inc. | Paper for corrugating medium |
| DE19816931C2 (en) * | 1998-04-16 | 2001-12-13 | Bhs Corr Masch & Anlagenbau | Heating device for a moving material web, in particular preheaters for a corrugated cardboard system |
| SI2675907T1 (en) | 2011-02-14 | 2018-04-30 | Xyleco, Inc. | Processing paper feedstocks |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3004880A (en) * | 1959-10-28 | 1961-10-17 | Honeywell Regulator Co | Control method and apparatus |
| US3886019A (en) * | 1970-05-20 | 1975-05-27 | Alton Box Board Co | Method of making laminated corrugated paperboard |
| US3892613A (en) * | 1971-07-22 | 1975-07-01 | Int Paper Co | Method of making corrugated paperboard |
| JPS4862877A (en) * | 1971-12-08 | 1973-09-01 | ||
| US3920496A (en) * | 1972-02-22 | 1975-11-18 | Michael C Wilkinson | Corrugated paperboard and its method of manufacture |
| JPS498036A (en) * | 1972-05-11 | 1974-01-24 | ||
| DE2329300A1 (en) * | 1973-06-08 | 1975-01-02 | Bayer Ag | NEW POLYISOCYANATES AND METHODS FOR THEIR PRODUCTION |
-
1975
- 1975-07-07 US US05/593,833 patent/US4038122A/en not_active Expired - Lifetime
-
1976
- 1976-02-27 CA CA246,742A patent/CA1070229A/en not_active Expired
- 1976-06-26 JP JP51075960A patent/JPS5224797A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| JPS5224797A (en) | 1977-02-24 |
| US4038122A (en) | 1977-07-26 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CA1070229A (en) | Method and apparatus for fabricating corrugated board from poly-coated paper | |
| JP3391794B2 (en) | Method and apparatus for making helical carrier sleeves for printing cylinders and articles thereof | |
| CA1298767C (en) | Process for on-line lamination of plastic film in a corrugator for making corrugated paperboard | |
| US5783006A (en) | Automated fabrication of corrugated paper products | |
| CA1071988A (en) | Process control system for corrugators | |
| US5746854A (en) | Method of making mineral fiber insulation batt impregnated with coextruded polymer layering system | |
| US4861409A (en) | Process and apparatus for forming laminate by thermocompression bonding | |
| US4806183A (en) | Method of and apparatus for controlling application of glue to defined areas | |
| US5733624A (en) | Mineral fiber insulation batt impregnated with coextruded polymer layering system | |
| CA2604142C (en) | Method and apparatus for producing a corrugated product | |
| US4134781A (en) | Method for controlling warp in the manufacture of corrugated paperboard | |
| EP2391505A1 (en) | Method for moisture and temperature control in corrugating operation | |
| AU3178889A (en) | Method of and apparatus for manufacturing biaxially oriented film | |
| US4071392A (en) | Automatically controlled machine for making double-faced polyboard | |
| US4202723A (en) | Automatically controlled machine for making double-face, polymer plastic coated, corrugated paperboard | |
| US6692602B1 (en) | Machine for producing a corrugated cardboard sheet and process for calibrating the glue gap of such a machine | |
| US4360538A (en) | Glue machine automatic rider roll | |
| US3960475A (en) | Angular indexing mechanism | |
| US4887365A (en) | Apparatus for continuously drying coating layer on web | |
| US6050055A (en) | Apparatus and method for sealing of paperboard containers using induction heated metal bands | |
| US6540862B1 (en) | Method and apparatus for enhancing film adhesion when extruding polyethylene terephthalate onto paperboard | |
| EP1233906B1 (en) | Heated wheel for application of heat-activated or pressure sensitive precoated adhesive tape or string | |
| JP3492305B2 (en) | Bonding sheet material manufacturing system | |
| US5098512A (en) | Heating amount adjusting device for a preheater in a corrugated cardboard producing machine | |
| US6289960B1 (en) | Apparatus having a wrapped roll for making a single faced corrugated board |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |